Via formation in integrated circuit interconnects

ABSTRACT

An integrated circuit and manufacturing method therefor is provided having a semiconductor substrate with a semiconductor device. A first channel dielectric layer over the semiconductor has a first opening lined by a first barrier layer and filled by a first conductor core. A via dielectric layer having a via opening which is open to the first conductor core is formed over the first channel dielectric layer. A second channel dielectric layer with a second opening which is open to the via is formed over the via dielectric layer. A second conductor core fills the via and second channel openings. A second barrier layer lining the via and second channel openings under the second conductor core forms a barrier between the second conductor core and the via and second channel dielectric layers, but does not form a barrier between the first and the second conductor cores.

TECHNICAL FIELD

The present invention relates generally to semiconductor technology and more specifically via contact regions in integrated circuit interconnects.

BACKGROUND ART

In the manufacture of integrated circuits, after the individual devices such as the transistors have been fabricated in and on a semiconductor substrate or wafer, they must be connected, or “wired”, together to perform the desired circuit functions. This interconnection process is generally called “metallization” and is performed using a number of different photolithographic, deposition, and removal processes to create contacts to the transistors, wire/channels to the contacts, and vias interconnecting the channels where there are more than one level of channels.

There are a number of different metalization techniques, but generally, a device dielectric layer is deposited over the transistors, openings are formed through the device dielectric layer down to transistor junctions and gates, and the openings are filled with a conductive metal to form contacts.

In one technique called the “single damascene” or “single inlaid” process, the formation of the first channels starts with the deposition of a thin first channel stop layer on the device dielectric layer. The first channel stop layer is an etch stop layer which is subject to a photolithographic processing step which involves deposition, patterning, exposure, and development of a photoresist, and an anisotropic etching step through the patterned photoresist to provide openings to the contacts. The photoresist is then stripped.

A first channel dielectric layer is formed on the first channel stop layer. Where the first channel dielectric layer is of an oxide material, such as silicon oxide (SiO₂), the first channel stop layer is a nitride, such as silicon nitride (SiN), so the two layers can be selectively etched. The first channel dielectric layer is then subject to further photolithographic process and etching steps to form first channel openings in the pattern of the first channels. The photoresist is then stripped.

An optional thin adhesion layer is deposited on the first channel dielectric layer over the entire semiconductor wafer and lines the first channel openings to ensure good adhesion of subsequently deposited material to the first channel dielectric layer. The adhesion layer is a metal such as tungsten (W), titanium (Ti), or tantalum (Ta).

High conductivity metals, such as copper (Cu), diffuse easily through dielectric materials such as silicon oxide and silicon nitride. This diffusion can result in a conductive buildup and cause short circuits in the integrated circuits. To prevent diffusion, a diffusion barrier is deposited on the adhesion layer. For copper conductor materials, the diffusion barrier layer is composed of materials such as tantalum nitride (TaN), titanium nitride (TiN), or tungsten nitride (WN).

However, these nitride compounds have relatively poor adhesion to copper and relatively high electrical resistance so they are problematic. For simplicity, the adhesion and barrier layers are sometimes collectively referred to as a “barrier” layer herein.

For conductor materials, such as copper and copper alloys, which are deposited by electroplating, a seed layer is deposited on the barrier layer and lines the barrier layer in the first channel openings to act as an electrode for the electroplating process. Processes such as electroless, physical vapor, and chemical vapor deposition are used to deposit the seed layer.

A first conductor material is electroplated on the seed layer and fills the first channel opening. The first conductor material and the seed layer generally become integral, and are often collectively referred to as the conductor core when discussing the main current-carrying portion of the channels.

A chemical-mechanical polishing/planarization (CMP) process is then used to remove the first conductor material, the seed layer, and the barrier layer above the first channel dielectric layer so the materials and layers are coplanar with the dielectric layer. The CMP process leaves the first conductor “inlaid” in the first channel dielectric layer to form the first channels. When a thing dielectric layer is placed over the first channels as a final layer, it is called a “capping” layer and the single damascene process is completed. When the layer is processed further for placement of additional channels over it, the layer is a via stop layer.

In another technique called the “dual damascene” or “dual inlaid” process, vias and channels are formed at the same time, generally over a completed single damascene process series of first channels. Effectively, two levels of channels of conductor materials in vertically separated planes are separated by an interlayer dielectric (ILD) layer and interconnected by the vias.

The initial step of the dual damascene process starts with the deposition of a thin via stop layer over the first channels and the first channel dielectric layer if it has not already been deposited as a capping layer. The via stop layer is an etch stop layer which is subject to photolithographic processing using a photoresist and anisotropic etching steps to provide openings to the first channels. The photoresist is then stripped.

A via dielectric layer is formed on the via stop layer. Again, where the via dielectric layer is of an oxide material, such as silicon oxide, the via stop layer is a nitride, such as silicon nitride, so the two layers can be selectively etched. The via dielectric layer is then subject to further photolithographic process using a photoresist and etching steps to form the pattern of the vias. The photoresist is then stripped.

A second channel dielectric layer is formed on the via dielectric layer. Again, where the second channel dielectric layer is of an oxide material, such as silicon oxide, the via stop layer is a nitride, such as silicon nitride, so the two layers can be selectively etched. The second channel dielectric layer is then subject to further photolithographic process and etching steps to simultaneously form second channel and via openings in the pattern of the second channels and the vias. The photoresist is then stripped.

An optional thin adhesion layer is deposited on the second channel dielectric layer and lines the second channel and the via openings.

A barrier layer is then deposited on the adhesion layer and lines the adhesion layer in the second channel openings and the vias.

Again, for conductor materials such as copper and copper alloys, a seed layer is deposited on the barrier layer and lines the barrier layer in the second channel openings and the vias.

A second conductor material is electroplated on the seed layer and fills the second channel openings and the vias.

A CMP process is then used to remove the second conductor material, the seed layer, and the barrier layer above the second channel dielectric layer to form the second channels. When a layer is placed over the second channels as a final layer, it is called a “capping” layer and the dual damascene process is completed.

The layer may be processed further for placement of additional levels of channels and vias over it. Individual and multiple levels of single and dual damascene structures can be formed for single and multiple levels of channels and vias, which are collectively referred to as “interconnects”.

The use of the single and dual damascene techniques eliminates metal etch and dielectric gap fill steps typically used in the metallization process for conductor metals such as aluminum. The elimination of metal etch steps is important as the semiconductor industry moves from aluminum (Al) to other metallization materials, such as copper, which are very difficult to etch.

A major problem occurs at the interconnection of the channels with the vias. Since the barrier layer is deposited over the first channel in the via, the barrier layer prevents interconnect diffusion, especially with copper. When current flow through the via causes electro-migration of copper from the via, the copper is not made up from the first channel and this leads to voids in the via, which can lead to increased circuit resistance and open circuits.

The barrier layer deposited in the via over the first channel in addition causes high-contact resistance and introduces flux divergence. Both increase electromigration, which leads to voids and reduced integrated circuit lifetime.

Solutions to these problems have been long sought but have long eluded those skilled in the art.

DISCLOSURE OF THE INVENTION

The present invention provides an integrated circuit and manufacturing method therefor having a semiconductor substrate with a semiconductor device. A first channel dielectric layer over the semiconductor has a first opening lined by a first barrier layer and filled by a first conductor core. A via dielectric layer having a via opening which is open to the first conductor core is formed over the first channel dielectric layer. A second channel dielectric layer with a second opening which is open to the via is formed over the via dielectric layer. A second conductor core fills the via and second channel openings. A second barrier layer lining the via and second channel openings under the second conductor core forms a barrier between the second conductor core and the via and second channel dielectric layers, but does not form a barrier between the first and the second. conductor cores. The absence of the barrier between the first and the second conductor cores reduces contact resistance and eliminates flux divergence to eliminate voids and increase integrated circuit lifetime.

The above and additional advantages of the present invention will become apparent to those skilled in the art from a reading of the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 (PRIOR ART) is a plan view of aligned channels with a connecting via;

FIG. 2 (PRIOR ART) is a cross-section of FIG. 1 (PRIOR ART) along line 2—2; and

FIG. 3 is a cross-section of a semiconductor wafer similar to that shown in FIG. 2 (PRIOR ART) in an intermediate stage of manufacture; and

FIG. 4 is a cross-section similar to that shown in FIG. 2 (PRIOR ART) of a semiconductor wafer of the present invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to FIG. 1 (PRIOR ART), therein is shown a plan view of a semiconductor wafer 100 including a silicon semiconductor substrate (not shown) having as interconnects first and second channels 102 and 104 connected by a via 106. The first and second channels 102 and 104 are respectively disposed in first and second channel dielectric layers 108 and 110. The via 106 is an integral part of the second channel 104 and is disposed in a via dielectric layer 112.

The term “horizontal” as used in herein is defined as a plane parallel to the conventional plane or surface of a wafer, such as the semiconductor wafer 100, regardless of the orientation of the wafer. The term “vertical” refers to a direction perpendicular to the horizontal as just defined. Terms, such as “on”, “above”, “below”, “side” (as in “sidewall”), “higher”, “lower”, “over”, and “under”, are defined with respect to the horizontal plane.

Referring now to FIG. 2 (PRIOR ART), therein is shown a cross-section of FIG. 1 (PRIOR ART) along line 2—2. A portion of the first channel 102 is disposed in a first channel stop layer 114 and is on a device dielectric layer 116, which is on the silicon semiconductor substrate. Generally, metal contacts are formed in the device dielectric layer 116 to connect to an operative semiconductor device (not shown). This is represented by the contact of the first channel 102 with a semiconductor contact 118 embedded in the device dielectric layer 116. The various layers above the device dielectric layer 116 are sequentially: the first channel stop layer 114, the first channel dielectric layer 108, a via stop layer 120, the via dielectric layer 112, a second channel stop layer 122, the second channel dielectric layer 110, and a capping or via stop layer 124.

The first channel 102 includes a barrier layer 126, which could optionally be a combined adhesion and barrier layer, and a seed layer 128 around a conductor core 130. The second channel 104 and the via 106 include a barrier layer 132, which could also optionally be a combined adhesion and barrier layer, and a seed layer 134 around a conductor core 136. The barrier layers 126 and 132 are used to prevent diffusion of the conductor materials into the adjacent areas of the semiconductor device. The seed layers 128 and 134 form electrodes on which the conductor material of the conductor cores 130 and 136 is deposited. The seed layers 128 and 134 are of substantially the same conductor material as the conductor cores 130 and 136 and become part of the respective conductor cores 130 and 136 after the deposition.

In the past, for copper conductor material and seed layers, highly resistive diffusion barrier materials such as tantalum nitride, titanium nitride, or tungsten nitride were used as barrier materials to prevent diffusion. In addition to increasing the overall resistance of the semiconductor chip which contained all the semiconductor devices, the barrier region 138 would block diffusion of copper from the conductor core 130 to the conductor core 136 as electro-migration caused the movement of copper atoms out of the via 106 and allowed the formation of voids therein.

The barrier layer deposited over the first channel in the via in addition causes high-contact resistance and introduces flux divergence.

Referring now to FIG. 3, therein is shown a cross-section similar to that shown in FIG. 2 (PRIOR ART) of a semiconductor wafer in an intermediate stage of manufacture. The semiconductor wafer 200 has a first channel 202 disposed in a first dielectric layer 208. A portion of the first channel 202 is disposed in a first channel stop layer 214 and is on a device dielectric layer 216. Generally, metal contacts (not shown) are formed in the device dielectric layer 216 to connect to an operative semiconductor device (not shown). This is represented by the contact of the first channel 202 with a semiconductor device gate 218 embedded in the device dielectric layer 216. The various layers above the device dielectric layer 216 are sequentially: the first channel stop layer 214, the first channel dielectric layer 208, a via stop layer 220, the via dielectric layer 212, a second channel stop layer 222, and the second channel dielectric layer 210.

The first channel 202 includes a barrier layer 226 and a seed layer 228 around a conductor core 230. Openings have been formed in the via dielectric layer 212, the second channel stop layer 222, and the second channel dielectric layer 210. A barrier layer 232 has been deposited in the openings. A portion of the barrier layer 232 indicated by the arrow 238 is removed by a sputtering process 240 to expose the first conductor core 230 at the bottom of the via 206. The sputtering process 240 is the beginning of the deposition of a seed layer by physical vapor deposition (PVD), ionized metal plasma (IMP), or hollow cathode magnetron (HCM) sputtering. During the deposition of a seed layer 234, the bias power to the wafer 200 is increased to cause back sputtering of the barrier material at the bottom of the via opening onto the barrier layer 232 of the sidewall. This process strengthens the sidewall barrier coverage while removing the barrier layer from the bottom. It will be noted that the entire barrier layer does not have to be removed from the conductor core 230 and the seed layer 228 in order to receive the benefits of the present invention. The sputtering process 240 continues until a seed layer 234 is formed.

Referring now to FIG. 4, therein is shown a cross-section similar to that shown in FIG. 2 (PRIOR ART) of a semiconductor wafer 200 of the present invention. The process continues from FIG. 3 to form the final structure of FIG. 4. The semiconductor wafer 200 has first and second channels 202 and 204 connected by a via 206. The first and second channels 202 and 204 are respectively disposed in first and second dielectric layers 208 and 210. The via 206 is a part of the second channel 204 and is disposed in a via dielectric layer 212.

A portion of the first channel 202 is disposed in a first channel stop layer 214 and is on a device dielectric layer 216. Generally, metal contacts (not shown) are formed in the device dielectric layer 216 to connect to an operative semiconductor device (not shown). This is represented by the contact of the first channel 202 with a semiconductor device gate 218 embedded in the device dielectric layer 216. The various layers above the device dielectric layer 216 are sequentially: the first channel stop layer 214, the first channel dielectric layer 208, a via stop layer 220, the via dielectric layer 212, a second channel stop layer 222, the second channel dielectric layer 210, and a next channel stop layer 224.

The first channel 202 includes a barrier layer 226 and a seed layer 228 around a conductor core 230. The second channel 204 and the via 206 include a barrier layer 232 and a seed layer 234 around a conductor core 236. The barrier layers 226 and 232 are used to prevent diffusion of the conductor materials into the adjacent areas of the semiconductor device. The seed layers 228 and 234 form electrodes on which the conductor material of the conductor cores 230 and 236 is deposited. The seed layers 228 and 234 are of substantially the same conductor material of the conductor cores 230 and 236 and become part of the respective conductor cores 230 and 236 after the deposition.

In the above structure, it will be noted that there is no barrier layer at the contact point between the via 206 and the first channel 202 in a region designated as region 244. Due to the lack of the barrier layer 232 in the region 244, the contact resistance is decreased, there is enhanced electromigration resistance, and reduced flux divergence.

In various embodiments, the diffusion barrier layers are of materials such as tantalum (Ta), titanium (Ti), tungsten (W), alloys thereof, and compounds thereof. The adhesion layers are of materials such as tantalum nitride (TaN), titanium nitride (TiN), tungsten nitride (WN), and compounds thereof. The seed layers (where used) are of materials such as copper (Cu), gold (Au), silver (Ag), , an alloy thereof, and a compound thereof with one or more of the above elements. The conductor cores with or without seed layers are of conductor materials such as copper, aluminum (Al), gold, silver, , an alloy thereof, and a compound thereof. The dielectric layers are of dielectric materials such as silicon oxide (SiO_(x)), tetraethoxysilane (TEOS), borophosphosilicate (BPSG) glass, etc. with dielectric constants from 4.2 to 3.9 or low dielectric constant dielectric materials such as fluorinated tetraethoxysilane (FTEOS), hydrogen silsesquioxane (HSQ), benzocyclobutene (BCB), TMOS (tetramethoxysilane), OMCTS (octamethyleyclotetrasiloxane), HMDS (hexamethyldisiloxane), SOB (trimethylsilil borxle), DADBS (diaceloxyditerliarybutoxsilane), SOP (trimethylsilil phosphate), etc. with dielectric constants below 3.9. The stop layers and capping layers (where used) are of materials such as silicon nitride (Si_(x)N_(x)) or silicon oxynitride (SiON).

While the invention has been described in conjunction with a specific best mode, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the aforegoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and scope of the included claims. All matters hither-to-fore set forth or shown in the accompanying drawings are to be interpreted in an illustrative and non-limiting sense. 

The invention claimed is:
 1. An integrated circuit comprising: a semiconductor substrate having a semiconductor device provided thereon; a first dielectric layer on the semiconductor substrate having a first channel opening provided therein; a first barrier layer lining the first opening; a first conductor core over the first barrier layer filling the first opening and connect to the semiconductor device and forming a first channel; a via dielectric layer over the first dielectric layer having a via opening provided therein; a second dielectric layer over the via dielectric layer having a second channel opening provided therein; a second barrier layer lining the via and second channel openings, the second barrier layer thicker in the via opening than in the second channel opening and having an opening provided therein to the first channel; and a second conductor core to fill the via and second channel openings and form a second channel and via.
 2. The integrated circuit as claimed in claim 1 wherein the first, second, and via dielectric layers are of a low dielectric constant dielectric material.
 3. The integrated circuit as claimed in claim 1 wherein the first and second barrier layer are of a metal from a group consisting of tantalum, titanium, tungsten, an alloy thereof, and a compound thereof.
 4. The integrated circuit as claimed in claim 1 wherein the first and second conductor cores are of a material from a group consisting of copper, aluminum, gold, silver, an alloy thereof, and a compound thereof.
 5. An integrated circuit comprising: a semiconductor substrate having a semiconductor device provided thereon; a device dielectric layer on the semiconductor substrate; a first channel dielectric layer on the device dielectric layer and having a first channel opening provided therein; a first barrier layer lining the first channel opening; a first seed layer over the first barrier layer; a first conductor core filling the first channel opening and connecting to the semiconductor device and forming a first channel; a via dielectric layer over the first channel dielectric layer and having a via opening provided therein; a second channel dielectric layer over the via dielectric layer and having a second channel opening provided therein; a second barrier layer lining the via and second channel openings, the second barrier layer thicker in the via opening than in the second channel opening and having an opening provided therein to the first channel; a second seed layer over the second barrier layer; a second conductor core to fill the via and second channel openings and form a second channel and via, the via in contact with the first channel.
 6. The integrated circuit as claimed in claim 5 wherein the first, second, and via dielectric layers are of a low dielectric constant dielectric material.
 7. The integrated circuit as claimed in claim 5 wherein the first and second barrier layer are of a metal from a group consisting of tantalum, titanium, tungsten, an alloy thereof, and a compound thereof.
 8. The integrated circuit as claimed in claim 5 wherein the first and second conductor cores are of a material from a group consisting of copper, aluminum, gold, silver, an alloy thereof, and a compound thereof.
 9. The integrated circuit as claimed in claim 5 wherein the first and second seed layers are of a material from a group consisting of copper, aluminum, gold, silver, an alloy thereof, and a compound thereof. 